Now, it’s time to cut the recesses for the candles. I had originally thought of using a Forstner bit, but it does not leave a smooth flat bottom to the recess. Instead, I used the Forstner bit to cut a pattern for use with my router. I plan to use a pattern bit with a bearing. Looks like it is time to build a jig! Since I am only building one of these, I’ll build a temporary jig. The same elements can be used to create a smaller, but permanent jig.

I have two hole sizes so I can figure out which to use. I’m going with the 1 7/8” size. Now I need a way to position the pattern in an accurate, consistent and rigid manner. My plan is to use a fixed position jig and move the arched piece. I need to start with a reference edge. I found a fairly large piece of MDF in my sheet stock inventory (that’s fancy talk for a pile of plywood and stuff).

To this I added a reference to keep the pattern perpendicular to the reference edge.

The next step is to add blocking to set the pattern at the right height. Then add a stop block to center the pattern over the arched piece.

You can also see I have blocks against the sides of the arch to hold the piece against the reference edge and at each end.

You can see a piece of oak under the block that holds the pattern up at the near end. There is another one under the other end of the pattern. As I get near the end of the arch, I need to lower the pattern to get my router bit to reach. I’ll remove these pieces of oak when that time comes.

I need to figure out a resonable number of candles and a spacing. I know I want one candle at the center so that means an odd number. After playing with numbers for a while, I take a detour into the house and fire up Excel. A couple of equations and I come up with 9 candles and a center-to-center spacing of 3.18” (a little less than 3 3/16”)

I cut a spacing block to this dimension. After I cut the center pocket, I release the right hand end block. Then I slide the arch to the right and put the spacer block in.

I then push the arch against the block and re-clamp the right end block. Next I pull out the spacing block and reposition the left end block and the side blocks. After I cut the next pocket, I flip the piece end for end to cut the same pocekt on the opposite end.

Here is the end result. Nine evenly spaced pockets with smooth flat bottoms!